SPE-178092-MS

Case Study: Quick Production Facility

Amol Diware, Milind Khati, and Zaharia Stoianovici, Halliburton; Sunil Borase, Cairn India Ltd

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Oil and Gas India Conference and Exhibition held in Mumbai, India, 24 26 November 2015.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
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Abstract
An operator in India desired two modular, skid-mounted, plug-and-play quick production facilities (QPF)
with the capacity for quick relocation and commissioning within multiple fields. This paper discusses the
successful solution presented by the service company using an economic, flexible, and reliable QPF
model. It also discusses challenges related to flow assurance, limited infrastructure, and compliance with
the India Directorate General of Mines Safety (DGMS) challenges.
The QPF model consists of process skids, utility and storage systems, interconnected piping, data
acquisition (DAQ), and a power distribution system. The well flowline is routed through an indirect water
bath heater (IWBH) and three-phase separator. Oil from the separator transfers to the export oil storage
tank and loading gantry. Water travels to the evaporation pond through a skimmer tank, and gas is
transferred to the burn pit through a knockout drum (KOD). Liquid accumulated in the KOD is transferred
to the storage tank. A closed drain maintenance vessel and alarm system is also included.
The operator used a service company to engineer, procure, install, and commission two QPFs. From
a process perspective, the primary challenges encountered included flow assurance related to the presence
of a variety of oils and wax with high wax appearance temperature (WAT), limited existing infrastructure
in the very remote location, and compliance with the India DGMS standards. After all of the equipment/
skids arrived on location, the operator requested the installation of the QPFs within a short period of time.
A team consisting of local contractors and global personnel from various disciplines was assembled to
meet the challenge. This team included personnel from project management, mechanical and piping,
electrical and instrumentation, and construction and commissioning. The installation and commissioning
of the first QPF was completed in 45 days. After applying lessons learned from the first installation, the
second QPF installation was completed in only 25 days. The commissioning of the facilities in such a
short time period was the result of collaborative work from both the operator and the service company.
Two modular, skid-mounted, plug-and-play QPFs with the capacity for quick relocation and commissioning within multiple fields were installed in very remote locations in India. This paper discusses
challenges encountered and addressed during the operation using an economic, flexible, and reliable QPF
model. Lessons learned during the first operation enabled a much faster completion of the second QPF,
thus exceeding operator expectations.

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Introduction
The service company established the two QPFs for the operator in India in its onshore block. All process
skids, utility system, and interconnected piping were designed by the service company.
Multidisciplinary personnel, including engineering, procurement, logistics, and QA/QC specialists
worked for extended hours to complete the first challenge of this project, which was to mobilize all
equipment in country within 90 days. This was a large undertaking for everyone involved. The engineering team had to design the package, taking into consideration all HSE and quality standards. The
procurement and supply chain (PSCM) team had to determine the appropriate vendor for each item. The
manufacturer had to manufacture the equipment/skid within a short time while maintaining all HSE and
quality standards; the quality control personnel had to inspect all components in time, and the logistics
team had to mobilize all equipment in country. Everyone involved accepted this challenge and worked
hard to complete it within the given time. As a result, the service company mobilized all equipment within
90 days and, in the process, set a record of fastest mobilization ever accomplished by any service provider
company.
After all equipment/skids arrived at country, the second challenge was to install the QPF in short time.
The service company management had assigned the team to install the facilities at two locations. The team
consisted of personnel from several disciplines, including project manager, project supervisor, project
coordinator, project planner, installation lead, piping lead, electrical and instrumentation leads, and
commissioning leads, along with supporting teams for each discipline. The installation and commissioning of the first QPF was completed in 45 days; the second QPF was completed and commissioned in 25
days at a remote location. The service company QPF team worked intensively to complete both
installations in time. The operator team also supported the service company team in all disciplines
throughout the installation and commissioning. Finally, the operator and service company teams jointly
commissioned the plant and handed it over to begin production. Both facilities are running very well with
no operational issues.
The two QPFs, installed in the NI-2 and RAAG SB-1 fields, are designed for a production rate of 500
to 3,500 bbl fluid/day (the expected water cut is from 0 to a range of 500 to 1500 bbl/day. The facilities
are designed to handle both self-flow and artificial lift type flow wells. The QPF of the NI-2 field includes
two wells; the QPF of the RAAG SB-1 field includes one well. These facilities consist of well flowlines,
IWBH, three-phase separator, water separator, KOD, chemical injection system, necessary utilities, shut
down system, oil storage tanks, oil transfer pumps, and loading gantry. It also includes the complete power
distribution system with a synchronization panel and switch gear panel. All process skids (indirect heater,
three-phase separator, water separator, and storage tank) are thermally insulated. All process lines are
electrically heat traced and thermally insulated because the oil in these fields is heavy oil (API 16.7 to 35)
and contains wax content of up to 30%.
For process monitoring and data acquisition, a simplified wireless data acquisition system was
installed, which will help ensure complete monitoring and recording of system status and process flow
parameters (pressure, temperature, levels, and flow). This overall separation process is directly controlled
by production operators.
In the overall process flow design of this facility, the flowline from the well is routed through the
IWBH and three-phase separator. Oil from the separator will transfer to the export oil storage tank and
to the loading gantry to load the tankers. Water from the separator will be transferred to an evaporation
pond through the oil skimmer tank. A KOD will be used to transfer gas from the separator to the burn pit.
Any potential liquid accumulated in the KOD will be transferred back to the storage tank. A closed drain
vessel is also installed that will be used during maintenance in this facility in which all drains from the
heater, three-phase separator, and water separator will be collected and transferred back to the system for
further processing. This paper describes the challenges associate with this project

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Engineering
Detailed engineering was performed jointly by the operator and service company engineering team. The
operator provided the basic plot plan of the site to the service company, which the service company
engineering used as the basis for the preparation of the final interconnected piping layout. The final plot
plan was designed on the basis of the zone classification study. A HAZOP study was performed by both
parties. The service company performed the complete design and engineering for the process skids,
piping, electrical, and instrumentation. The design and engineering performed had to consider the
challenges of the wells and to provide an economical solution for these types of marginal fields, including
the following:

Heavy oils, API 16.7 minimal range

Large range of potential wells from 16.7 to 35 API
Presence of high content of wax of up to 30%
Very cold wells; reservoir temperature of 65 to 70C
Very low WAT point at 60C in surface conditions and very high pour point at 37C (fluid
practically becomes solid below 37C)
CO2 presence could range from 3.5% to 19 to 24%
Potential large water cut from 5 to 60%, expected heavy emulsion will be difficult to break
Remote location
No water available for steam generation
Full support facilities needed for operations
Minimal cost for economic model of a marginal field productivity

The selected engineering solution relied on the following:

Chemicals injection for flow assurance (multiple injection ports, ability to inject multiple chemicals
Heat support: indirect heater, heat traced lines, thermal protection of vessels, immersed rod heaters
into the crude storage vessels
Separator and water/oil skimmer tank, designed for extended retention time for fluid to support
separation
Run process at lowest pressure available to ensure low Reid vapor pressure (RVP) for transport
purpose
Full utilities support capabilities

The engineering work performed included the following:

Design the details and engineering of the flowline to the shutdown valve aligned with field-specific
reservoir data provided by the operator
The engineering and engineering management of the key equipment/package
Generate construction drawings/documents, including isometrics and piping general arrangement
drawings (GADs), and update documents and drawings to as built
Participate in technical safety studies conducted by the operator, including HAZOP, HAZID,
safety integrity level (SIL) identification for any design/configuration changes
The engineering scope used to complete this project, including process, mechanical and piping,
instrumentation and control, and electrical, is described in the following subsections.
Process
The process component of the engineering scope for this project includes the following:

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Update the process flow design (PFD) and the piping and instrumentation diagram (P&ID) in
accordance with the field-specific data.
Perform hydraulic calculations.
Provide the issue for construction (IFC) of the P&IDs that incorporates the vendor information.
Obtain the operators approval on design calculations, PFDs, and P&IDs.
Mechanical and Piping
The mechanical and piping component of the engineering scope for this project includes the following:

Perform a detailed review and incorporation of design and engineering, procurement, vendor
documents.
Inspect all mechanical and piping items based on the approved P&IDs and updated mechanical
data sheets.
Obtain the operators approval on the mechanical data sheets, design calculations, isometrics,
piping GADs, and vendor drawings.
Supervise the installation of equipment and packages, including interconnecting piping.
Supervise the pre-commissioning, cleaning, flushing, and commissioning, including leak testing.

Instrumentation and Control

The instrumentation and control component of the engineering scope for this project includes the
following:

Perform a detailed engineering, and document review, incorporation, and inspection of all
instrumentation as required by the approved P&IDs and approved instrument data sheets.
Generate an instruments list and cable schedule for the complete facility.
Obtain the operators approval on instruments data sheets and pressure safety valve (PSV) sizing
calculations.
Supervise the installation of the pneumatic emergency shut down (ESD) panel and all instrument
bulks.
Electrical
The electrical component of the engineering scope for this project includes the following:

Perform a detailed engineering, document review, and inspection of all electrical items as required
by the approved P&IDs, single line diagrams, and updated electrical data sheets.
Prepare single line diagrams of the electrical system based on detailed engineering.
Prepare an electrical load list specifying all load-bearing equipment for the complete facility.
Prepare the drawing for the power motor control panel (PMCC).
Obtain the operators approval on the electrical documents.

Procurement and Logistics

The need to mobilize the equipment in country in such a short timespan created a major challenge for the
service company personnel. Personnel from multiple disciplines (including engineering, procurement,
logistics, and QA/QC specialists) within the organization began working for extended hours to complete
the first challenge of this project: the mobilization of all equipment in country within 90 days. This was
large undertaking for everyone involved, including the engineering team, the PSCM team, the manufacturer, the QA/QC specialists, and the logistics team. The engineering team had to design the package,
taking into consideration of all HSE and quality standards; the PSCM team had to locate an appropriate
vendor for each item. The manufacturer had to manufacture the equipment/skid within a short time frame

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while honoring all HSE and quality standards. The QA/QC personnel had to inspect all items within the
allocated time frame, and the logistics team had to mobilize all equipment in country. Everyone involved
accepted this challenge and worked hard to complete it within the given time. As a result, the service
company mobilized all equipment within 90 days, establishing a record of the fastest mobilization ever
performed by any service provider company.
All equipment must be manufactured by reputable manufacturers. To support this requirement, the
service company used a large database of prequalified vendors and contractors for all materials and
services required. All purchases were to be made in accordance with the approved data sheets by the
operator, drawings, standards, and specifications. The service company engineering team authorized the
specialists to review the vendor documentation and the QA/QC personnel to perform the in-house
inspection. All equipment/packages were dispatched after the operators inspection (FAT) at the manufacturer facility.

Equipment Used in the QPF

Many types of equipment are used to create a QPF. This section provides an overview of the various types
of equipment used to complete this project.
Emergency Shut Down System
The emergency shut down system includes the pneumatic ESD panel and shutdown valve (SDV). This is
a multistation system that permits the monitoring of the status of the system and controls closure during
production stage in response to any emergency. Two SDVs are provided in process line. The first is
downstream of wellhead; the second is upstream of the IWBH to control any abnormality in the process
line. These SDVs are operated by a pneumatic-actuated ESD panel. The panel is also linked to fire and
gas (F&G) systems through electrical controllers. Aside from these, additional controls were included for
all process skids, as supplied with high-low pressure switches and high-low level switches to shut-in the
well in any abnormal condition. For example, the export oil storage tank includes high-low level switches;
after the tank is filled to a specified level, the level switches in the storage tank will close the SDV. These
switches are all pneumatically operated through ESD panel. Push-buttons are provided at various locations
to be used to manually shut down the plant in an abnormal condition.
An F&G detection system is also provided in the facility, which is interconnected with the ESD system,
which will enable a complete plant shut down in the event of an abnormal situation.
Data Header/Manifold
The manifold provides additional pressure gauge, thermo well, sampling, and injection ports. Two data
headers are installed in this facility. The first is located downstream of the wellhead; the second is located
downstream of the IWBH. Stainless steel (SS) tubing is used for interconnected lines from the chemical
injection skid to both data headers.
Chemical Injection Package
The chemical injection package consists of four pumps and tanks, which will be used to inject specific
chemicals to aid in separation (demulsifies/emulsion breakers), maintain wax in suspension (wax inhibitors, wax dispersants), and inject corrosion inhibitors. Lines from the chemical injection skid to both data
headers are connected through SS tubing.
Indirect Water Bath Heater (IWBH)
The IWBH is used to heat the fluid stream produced at the surface, which helps to prevent hydrates,
paraffin formation, and choke ups in flow systems. It is also used to support emulsion breaking and to
promote the effectiveness of the demulsifier agent injected.
This skid-mounted IWBH is used to increase the temperature of well fluids to facilitate the phase
separation process. All piping and ancillary equipment are fitted within the skid. The indirect-fired heater

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uses a vessel for a water bath at atmospheric pressure. The water is heated by a diesel/gas dual fueled
firebox that feeds a heating coil in the lower part of the water bath. The high pressure process flow coils
are located above the heating coil in the hottest part of the water bath. Controls and safety equipment
include a temperature controller with a pilot shut down monitor, a flame arrestor on the burner air inlet,
and a spark arrestor on the burner flue exhaust. To improve the temperature range and heat transfer, a mix
of 50% water/glycol agent is used; this helps ensure an additional 8 to 10C temperature for the fluids
heated, which is needed for process efficiency.
Three-Phase Separator
The three-phase horizontal test separator provides a means to safely and efficiently separating and
measuring the oil, gas, and water produced from the reservoir. The horizontal test separator is a
self-contained unit with the valves and pneumatic controls needed to regulate the vessel pressure and fluid
levels during a well test. The redundant safety design incorporates pre-set safety relief valves and a rupture
disc assembly. The separator vessel is thermally isolated. The design of the separator enables a 10-min
retention time for the fluids to be exceeded.
Water Separator/Oil Skimmer Tank
The water separator/oil skimmer tank is used to further separate the oil and gas from produced water. This
vessel was designed to allow an extended retention time for water (more than 75 min). It can also be used
as a second stage separator. The water separator consists of a level measuring system with sight glasses
or magnetic levels. To prevent overpressure and overfilling, the vessel is fitted with a pressure-relief valve
and a high- and low-level alarm system. The vessel is designed with a diverter, vortex breaker, and
stiffening rings capable of withstanding a vacuum in the vessel. The vessel is thermally isolated. A level
in the separator is controlled by a guide wave radar level and interface transmitter, which automatically
control water and oil discharge pumps. The process is designed at a very low pressure to ensure depth in
water degasing and oil separation.
Water from the water oil/skimmer tank is transferred to either an evaporation pond or to the loading
gantry for further transfer. Oil from water/oil skimmer tank will be transferred to the export oil storage
tank, and gas joining the LP collector is diverted to the flare pit by means of a KOD.
Export Oil Storage Tank
Two crude oil export storage tanks are provided in each QPF. These tanks are used to store export oil,
which will further transferred to the loading bay to load the tankers. The controls for the 500 bbl tanks
are set on two separate systems, and consist of both of high- and low-level switches, as well as wireless
level monitoring. Vent lines are with equipped flame arrestors for fire protection. The vessels are designed
with multiple immersed rod heaters installed on the lower part of the tank, which are automatically
controlled; these rod heaters will maintain the crude oil at a temperature above the WAT (60 C). The
design temperature is 75 C, which will maintain the crude oil at fluid conditions for transfer. The vessel
is thermal insulated.
Oil/Water Transfer Pump
Oil/water transfer pumps are installed to transfer the oil from the storage tank to the loading bay, water
from the water separator to the evaporation pit, and oil from the water separator to the oil storage tanks.
The pumps are fitted with an explosion-proof electrical motor for operations in Zone 2 regions.
Air Compressor Package
The air compressor package includes a compressor and a dryer. Air is required to operate all pneumatically operated for level and pressure switches and for the ESD pilots system. Each package includes two
air instrument compressors, each of which includes compressed air tanks. The specific solution selected
for air compressors includes two motors/pumps that can be used as back-ups. The air instrument pressure
is set at 125 psi, as required by the ESD panel, to charge and operate various switches to regulate the air

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supply in accordance with requirements. Each compressed air tank has a capacity of 1000 L; the air
reserve will provide a 20 to 30 min air supply in the event of a shutdown.
Fire Water Tank and Fire Fighting System
One fire water tank (500 bbl) is provided at each location, along with all required surface equipment,
including a pump, piping, fixed fire monitor, portable hose reels, and hydrants.
Diesel Storage System
Each QPF is provided with 250 bbl diesel tank to store diesel, which includes two transfer pumps and
interconnected piping. Pipe lines are extended from the diesel tank to the IWBH, the diesel generator, and
the fire water pump.
Loading Bay/Gantry
The overhead loading bay/gantry is provided to load the tankers, and consists of a loading arm. The design
allows two trucks to be loaded simultaneously with a minimum loading time of 30 to 35 minutes. The
loading arms are positioned for top loading with minimal human interface; they are also equipped with
overfill vibration sensors set to automatically shutdown the crude oil transfer pumps.
Data Acquisition System (DAQ)
For process monitoring and data acquisition, a wireless DAQ system is provided for complete monitoring
and recording of system status and flowing parameter by means of pressure, temperature, and flow
transducers. This process is controlled by production operators. Wireless DAQ provides an easy, reliable,
and accurate system. This system is used to wirelessly acquire data from various data collection and
transmitting ports, including pressure, differential pressure, temperature, and flow rate. Data are collected
by the logger and computed by the computer with software. The calculation and graph plotting is
performed in real time. The frequency of the data received can be set to be frequently as one second.
Electrical Heat Tracing (EHT) and Thermal Isolation System
All process skids are thermally isolated. Electrical heat tracing and thermal isolation are provided for all
process flowlines as a part of the flow assurance system. The EHT panels are installed to control each
individual line system, as well as the MCC into the power distribution control room.
Piping Package and Flare System
All interconnected piping between the skids is provided by the service company. Various types of piping,
i.e., 600#, 900#, and 1500# rated piping, are provided depending on the well parameters and processes.
The main process fluid line, i.e., the oil line from the wellhead to the loading bay through the IWBH,
separator, and storage tank, is electrically heat traced and thermally isolated. Other lines are provided with
thermal isolation for personnel protection.
As a solution for gas flaring, a ground horizontal flare and a specific flare pit were selected. The flare
system is installed to burn the gas safely and is designed to exceed the largest potential flow rate. This
system includes a specific flare tip and dynamic seal. The flare tip is equipped with ignition and pilot
systems which provide permanent flaring of gases through the flare.
Knockout Drum
As a part of the flare system, a specific KOD is installed. The gas from the three-phase separator and water
separated is directed to the KOD and then through the flare tip to the burn pit. The KOD acts as a
gas-liquid separator, ensuring there are no drops of liquid going to the flare to be burned. High-low level
switches are installed in the KOD to monitor the liquid level. Liquid collected in the KOD is diverted to
the oil export storage tank. Two transfer pumps installed in parallel are provided to transfer the liquid back
to separator.
Closed Drain Vessel
The closed drain vessel collects the drains from the process skids, i.e., three-phase separator, water
separator, and the IWBH. The closed drain vessel is generally used during plant maintenance. The liquid

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gathered in the closed drain system is typically water that is contaminated with oil. The closed drain vessel
is equipped with a vertical pump that will circulate liquids back into the process system. In this QPF, the
liquid is re-circulated to the flowline upstream of the IWBH for further processing.
Power Distribution System
A complete power distribution system is installed in both QPFs. The power generation and distribution
were designed to include all systems needed for independent power control and for safe and smooth
transition to power from one generator to the second; a synchronization panel is used to synchronize the
power produced. The entire system includes diesel generators with 10 m height diesel generator stacks in
accordance with India-specific standards, switch gear panel/power and motor control center (PMCC),
synchronization panel, a full set of multiple transformers, uninterruptible power source (UPS) for 30 min
support, neutral ground resistant (NGR), and a complete earthing grid for the entire facility. This system
supplies power to complete facility, i.e., the IWBH, all motors, heaters in storage tanks, and area lighting,
by means of underground power, control, and instrument cabling system (more than 4,000 m of cabling
for each facility).
Containerized Equipment Lab
The laboratory cabin is a container where the computation of various data is performed. It is well equipped
with fire extinguishers, first aid kit, eye wash station, splash glass, and chemical gloves. The laboratory
includes complete instrumentation for process monitoring and control, such as oil and gas specific gravity
(SG), basic sediments and water (BS&W), gas % concentration, and water analyses.

Process Description
The fluids from the wells will be collected into a 3-in. ID inlet collector pipeline and directed toward the
production facility. The flanged connection piping used in the complete facility is in accordance with
ANSI standards with different ratings of 600, 900, and 1500 class. The main flowline and oil process fluid
lines are electrically heat traced and thermally insulated. For some liquid lines and gas lines, thermal
insulation has been provided as personnel protection.
Prior inlets in the production facility data header are installed which will allow multiple injection,
temperature, and pressure ports. A chemical injection package with four pumps is installed to inject
specific chemicals to aid separation (demulsifies/emulsion breakers), keep wax in suspension (wax
inhibitors, wax dispersants) and inhibit corrosion.
One SDV is installed just after the Christmas tree, i.e., near the well, to provide isolation of the flow
in the event of an emergency during production operations. The SDV valve is to be activated automatically by the high-low pilots or manually from multiple locations where ESD buttons are installed.
This system is designed to access the pump shut down system with an option to link it to the ESD
system to enable both to be coordinated in the event of shut down.
The flow passes through an indirect heat exchanger (water bath type), in which the well fluids
temperature will be increased to support emulsion breaking, water/oil/gas separation, and maintain the
wax above the WAT limit. The capacity of the indirect heater is 2.4 MMBHU/hr.
The indirect heater will have a dual-fuel system (diesel or gas), enabling it to use diesel at start-up
before the well flow established and gas is separated for fuel.
For the separation, the following range of horizontal vessels, three-phases, was proposed:

For the up to 400 to 500 bbl oil/day ( additional 500 bbl of water) facility, a three-phase separator
with 42-in. ID 12 ft. long at 1,440 psi
For the up to 1,000 bbl oil/day ( additional 1500 bbl water) facility. a three-phase separator with
42-in. ID 15 ft. long, at 1,440 psi

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These vessels will provide sufficient retention time for a thorough separation of oil, water, and gas,
over 10 min. The separator will have installed flow meters for oil and water and Daniel Senior orifice
for gas measurement. Two PSVs are installed on the three-phase separator safety devices to protect the
vessel and the system from any pressure increases.
The gas from first stage of separation is directed to a KOD and further to the flare/burn pit. As an
alternative, if there is sufficient gas flow from the well with a very low CO2%, this gas can be used as
gas fuel (natural gas generator and indirect heater). The KO pot acting as a gas scrubber unit will eliminate
any liquid phase. A ground flare pit is being considered for flaring the gas. The oil from the first stage
is to be diverted to the storage tanks.
To maintain the temperature above the WAT point, storage tanks are thermally isolated and have
electrical heaters installed. All lines from the separator to the storage tanks and further to the loading arms
are heat traced and thermally isolated.
Downstream of the temporary crude oil storage, two centrifugal pumps are installed in parallel with
10,000 bbl/day capacity each (1100% back up), which will transfer the oil from the tank farm to the road
tankers. These pumps will be manually operated by the production operators. A single pump will provide
a 30 to 35 min loading time for a 220 to 240 bbl road tanker size. Loading crude oil in the road tankers
will be performed by means of a 3-in. loading arm unit installed in a tower support structure.
The water from the first stage of separation is diverted to a skimmer tank/water separator, to further
separate the oil from the water stream. Oil skimmed will be transferred to storage tanks by means of an
electrical transfer pump.
Water from the skimmer tank is diverted to an evaporation tank/pond by means of two centrifugal
transfer pumps rigged up in parallel (1100% contingency).
A separate closed drain vessel is installed in both QPFs in which drains from all process skids will be
collected. Liquid from the closed drain drum (CDD) vessel will be recirculated to the IWBH for further
processing because this is water-contaminated oil.

Summary of Utilities
This section summarizes the types of utilities used in the QPF.
Power Generation
Two 1010 KVA (800KW) diesel generators (1100 % contingency) are installed which will supply
power to the entire plant, including the downhole pumps and other equipment that requires power, i.e.,
heaters, IWBH burner, and lighting. In the later stage, a power generation package was considered with
one natural gas fuel generator and a diesel fuel generator for backup. The complete package will include
electrical distribution boxes and an automatic transfer switch.
Heat Transfer
An IWBH is installed which is positioned upstream of the separator. The specification is for a 2 MM BTU
indirect heater with a dual-fuel system. The heat increase planned is from 60 to 65C to 87 to 92 C,
considering 50% water/glycol bath.
Five electrical heaters are installed in each of the temporary storage tanks. These tanks will be used for
oil storage at a temperature of approximately 70 to 75 C (significantly above the pour point).
Air Instrument
Air instruments required for the vessel level and pressure control switches and for the ESD pilots system
will be provided by two air instrument compressors, each including compressed air tanks. The air
instrument pressure is 125 psi, regulated to a lower operational pressure. Each compressed air tank has a
1000 L capacity; the air reserve will provide a 20 to 30 min air supply in the event of shut down.

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Gas Fuel
In this QPF, gas from first stage of separation will be directed to a KO pot/gas scrubber to eliminate all
potential liquids. The liquid separated will be regularly transferred to storage tanks. The gas from the KO
pot/gas scrubber will be directed to a natural gas generator (future scope) and indirect heater. If the
generators are down or if excess gas is produced, the excess will be directed to the flare pit.
Process Monitoring and Data Acquisition
For process monitoring and data acquisition, a wireless DAQ system is provided for complete monitoring
and recording of system status and flowing parameter by means of pressure, temperature, and flow
transducers. This process is controlled by production operators.
Fire Fighting
All surface-specific firefighting equipment is provided at the facility, as a QPF loop, designed to act
independently and in case of any emergency. A 500 bbl water tanks and independent diesel drive pump
will provide the volume and quantity needed for the first tier of firefighting.

Health, Safety, and Environment (HSE)

All HSE standards and guidelines/procedures have been taken into consideration in the complete project,
i.e., from engineering to the commissioning of the plant. There was a special focus on fulfilling all HSE
standards and procedures at each stage of the project execution. HAZOP and HAZID analyses has been
performed jointly by the operator and service company teams to help ensure that every piece of equipment
was manufactured to operate safely with no effect on the environment. All P&IDs and plot plans have
undergone HAZOP/HAZID. Similarly, safety studies were performed for the flare system. A complete fire
and gas mapping study was performed to determine the proper number of fire and gas detectors required
for entire facility and their particular locations. Complete execution was performed with no HSE
incidents. The total man hours for two locations (including installation and commissioning) are 71,546
man hours. The total LTI free man hours for two locations (including installation and commissioning) are
71,546 man hours.

Conclusion
The rapid equipment mobilization and installation of the facility has set a record for the service company.
The successful installation of these facilities has enabled the operator to flow the associated wells earlier
than would be otherwise possible; an early revenue cash flow enabled by this system can help to support
further field development. The QPF design would enable to facilities to be moved easily to a different
location, if required.